Case

Scrap tyre recycling facility, Houston, Texas

Genan

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Environmental company Genan is the largest tyre recycler in the world, processing up to 375,000 tonnes of end-of-life tyres (ELTs) annually. Sustainability is Genan's core value; and at Genan, we commit to striving for a sustainable future in every choice we make.

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The Genan Houston plant with a capacity of 100,000 tonnes of tyres/year is the latest plant in the Genan tyre recycling plant network.

At the end of the ’70s, the idea of establishing a plant for the recycling of scrap tyres was born. The automotive industry was booming and the waste problem with very slowly degrading scrap tyres in landfills and nature started to be addressed.

During the ’80s the idea was further developed, and in 1990, the first plant for recycling of scrap tyres became a reality in Viborg, Denmark. Through the ’90s the plant was continually improved and adjusted accordingly. The input capacity of the Danish plant is 35,000 tonnes of mixed scrap tyres (passenger car, van, truck, tractor and big earth moving tyres). Later the plant was extended to a full 70,000 tonnes/year.

Since then, 3 additional plants have been built in Germany with a capacity of between 65,000 and 70,000 tonnes of tyres/year, and May 2014 the world’s largest tyre recycling plant in Houston, Texas, USA, was ready for full operation, bringing the total Genan processing capacity to 375,000 tonnes of tyres/year.

The Genan scrap tyre recycling concept is unique. In a highly technological process, developed and optimized through practical experience over more than 20 years, all kinds of scrap tyres, may it be from passenger cars, vans, trucks, tractors or large earth moving machinery, are separated into the original elements: rubber, steel and textile.

The technology is completely automated. No human hand touches the tyres from start to end, and this ensures a consistent and high quality of the output. Other suppliers of recycled rubber are found in the marketplace, but none are able to produce a uniform, clean and consistent product like Genan.

The output from a Genan plant consists of 75% rubber powder and granulate, 14% steel, 14% textile and 10% waste, which primarily stems from impurities like sand and stones absorbed by the scrap tyres.
99% of the output is therefore recycled for good use in new applications which are able to substitute virgin materials.

The rubber is used in numerous applications, currently the most important being modification of asphalt and bitumen, infill in artificial turf and industrial rubber applications.

The steel is remelted in large steel works. The textile has so far been incinerated for energy recovery but is currently going through a comprehensive product development which will lead to final products within the noise and heat insulation industry.

 

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